Multi-Part Product Shipping Box and Display Tray

ABSTRACT

A reusable combined multi-part product shipping box and display tray. In one arrangement, the box includes two generally rectangular trays, each defining four sides, with four barrier portions projecting upward from each tray proximate its edges, one barrier portion at about the center of each of the sides, and four corner posts, one projecting up from each corner of the tray. The box includes a generally rectangular sleeve defining four sides and four corners, and open ends that are about the same size and shape as the trays, the sleeve adapted to engage with the trays to close its open ends and form a shipping container, the sleeve adapted to sit on the tray inside of and up against the barrier portions, with each corner of the sleeve located outside of and against a corner post, such that the sleeve is tightly engaged with the trays.

RELATED APPLICATIONS

This patent application is a continuation-in-part of U.S. patent application Ser. No. 12/640,246, entitled “Reusable, Combined Multi-Part Product Shipping Box and Display Tray,” filed on Dec. 17, 2009 which claims priority to U.S. Provisional Patent Application Ser. No. 61/138,220, entitled “Reusable, Combined Multi-Part Product Shipping Box and Display Tray,” filed on Dec. 17, 2008. The entire contents of the priority applications are hereby incorporated by reference in their entirety.

BACKGROUND

Bananas currently and historically have been shipped in a corrugated paper box consisting of a double wall Half Slotted Container (HSC) body covered by a single wall HSC full depth telescoping cover. These paper boxes are typically fabricated local to the banana plantations where they are assembled on a box-forming machine or by hand at the packing sheds on the banana plantations. The double wall bottom of the box is formed, in a secondary operation, and then packed with the bananas inverted or crown up to minimize transportation damage. Another box-making machine or individual forms the single wall top of the box which is then slid over the bottom of the box to the full depth of the container. When completed, the bananas are protected by the combined wall thicknesses in a paper box that has triple thick sidewalls, double wall bottom flaps and single wall top flaps.

The finished box is relatively expensive, typically over $1.25 per box and gets thrown out at the store level. It is a one-time use shipping container that generates about 2.5 pounds of waste for each 40 pound box of bananas.

After packing in boxes, the bananas are loaded into refrigerated containers and shipped to market. Another mode of transport to market is when the boxes of bananas are loaded into the hold of a ship without the container, just packed on pallets. With either method, upon arrival at port the bananas are shipped to ripening companies in various markets where they are ripened by a gas process. After the bananas are ripened, they are shipped to the stores.

At the store level, store personnel have to manually unpack each box of bananas and put them on display on store shelves, crown down, for customers to view and purchase. Accordingly, either the ripening supplier or the store personnel have to invert the cases or bunches of bananas by hand prior to lifting each bunch out and putting them on a display stand. Bananas are a high volume retail item. The unpacking and handling of bananas at the store level is very time consuming and labor intensive, costing the supermarkets labor and wasted time.

SUMMARY

By contrast to conventional packing boxes, embodiments of the present innovation relate to a reusable combined multi-part product shipping box and display tray. In one arrangement, the box or container can be used to ship bananas, other produce, or other goods, multiple times. The box, thus reduces the environmental impact of shipping millions of cases of bananas to market. The innovation reduces solid waste, energy consumption and greenhouse gases by approximately 60% when compared to the disposable paper box system described above.

The container also greatly reduces the costs associated with shipping. The paper box described above currently costs over $1.25 per unit. The container of the present innovation can decrease the cost per shipping cycle to approximately $0.20.

The three-part shipping container can minimize or eliminate the in-store labor associated with unloading each case of bananas by hand. This allows the supplier to invert each case of bananas prior to sending them to the store. Alternatively, the store personnel can invert an entire case at a time, place the case in the display area, remove the straps and lift the top tray and sleeve off the case, and the bananas are ready for display on the lower tray. This allows an entire tray of bananas to be displayed for sale with no further handling. A huge reduction of labor is thus achieved.

The container can be used for almost any other merchandise such as floral products that require lightweight, flexible display shippers. The size, strength and structure of the container can be readily modified as desired to suite the product being shipped. It can be customized to each specific item.

In one arrangement, embodiments of the innovation relate to a reusable combined multi-part product shipping box and display tray. There are two generally rectangular trays, each defining four sides, with four barrier portions projecting upward from each tray proximate its edges, one barrier portion at about the center of each of the sides, and four corner posts, one projecting up from each corner of the tray. There is also a generally rectangular sleeve defining four sides and four corners, and open ends that are about the same size and shape as the trays, the sleeve adapted to engage with the trays to close its open ends and form a shipping container, the sleeve adapted to sit on the tray inside of and up against the barrier portions, with each corner of the sleeve located outside of and against a corner post, such that the sleeve is tightly engaged with the trays.

In one arrangement, the trays are made of plastic and define an opening just inside of each post and that is sized and shaped to accept an identical post of another tray, to allow nesting of the trays. In one arrangement, the sleeve is manufactured of corrugated plastic and foldable into a flat form. In one arrangement, the posts are tapered from top to bottom where the bottom of the posts defines a wall portion that is essentially perpendicular to the top of the tray. The posts can include two sections at essentially ninety degrees to one another to form an “L” shaped configuration, one such section located on each of the two adjacent sides of the tray, so that each post engages with the two sides of the sleeve that meet at a corner of the sleeve.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other objects, features and advantages will be apparent from the following description of particular embodiments of the innovation, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of various embodiments of the innovation.

FIG. 1 is a top perspective view of an embodiment of a tray for a box assembly.

FIG. 2 is an exploded view of a sleeve for the box assembly in the process of being placed on the tray of FIG. 1.

FIG. 3 is an assembled view of the sleeve and tray of FIG. 2, illustrating the partially-assembled box ready to be filled with merchandise (such as bananas) that will be shipped in the box.

FIG. 4 shows the box assembly of FIGS. 1-3 fully assembled, with a second tray covering the open top of the assembly of FIG. 3; the Figure does not shown the removable bands or other devices used to hold the trays and sleeve together after the box has been filled.

FIG. 5 is an enlarged side view of one corner of the tray of FIG. 1, showing the post and barrier detail.

FIG. 6 is a top view of the die-cut blank used to make the sleeve shown in FIG. 2-4.

FIG. 7 is an enlarged view of the undersides of one corner of two of the trays shown in FIGS. 1-5, detailing the manner in which such trays nest for storage and shipment.

FIG. 8 illustrates an arrangement of a sleeve for the box assembly, according to one arrangement.

FIG. 9 illustrates an example of a schematic view of sleeve wall prior to sealing of the ends of the wall, according to one arrangement.

FIG. 10 illustrates an example of a schematic view of sleeve wall following the sealing of the ends of the wall, according to one arrangement.

DETAILED DESCRIPTION

As illustrated in FIGS. 1-4, a container or box assembly 10 consists of two substantially identical, injected molded tray, and one corrugated plastic sleeve that folds flat to minimize the storage and shipping space required once the box is broken down into its three parts.

The trays are relatively lightweight and strong. The trays are configured to be nested with each other for condensed return freight efficiencies. Also, each tray includes corner posts that help to align the corrugated plastic sleeve and locate the sleeve snugly on the tray. The corner posts include a tapered entry which transitions to a vertical 90-degree wall, which helps to lock the sleeve into position and pulls the sleeve sidewalls into a tight, rigid position for improved sleeve (container sidewall) stacking strength.

The trays further include vertical projections or barriers projecting upward from each of the four edges of the tray. These barriers limit or inhibit the sidewalls of the sleeve from expanding beyond the external perimeter of the tray. In one arrangement, the barriers are located centered on each of the four sides of the tray, at or close to the edges of the tray. The sleeve sits inside these barriers and rests up against them by the weight of the product pushing against the sleeve sidewalls.

The trays define ventilation holes in the center to provide weight reduction and top provide cooling and gas applications when pallets are shipped in the holds of ships, for example. The cooling gases come up from the floor of the pallet. Also, the trays can define various additional holes and cutouts in the tray for weight reduction. Weight control of the combined two trays and sleeve is important since a full truckload of bananas approaches the legal limit of weight a truck can safely carry.

The sleeve can be manufactured from a variety of materials. For example, the sleeve can be manufactured from corrugated polypropylene (i.e., plastic), such as 5 mm corrugated polypropylene, or any malleable material such as corrugated paper, injection molded plastic or corrugated polyethylene. When configured from corrugated plastic, the sleeves are relatively strong, lightweight, and unaffected by moisture or humidity. Additionally, when made from corrugated plastic, the sleeves can be machined on specialized machinery at a relatively low cost. Corrugated plastic can be mass produced at low cost to meet the volume requirements of a vast market. However, the sleeve could be made from any other material that has similar properties.

The sleeve, in one arrangement, has a desired quantity and size of ventilation holes cut out of the appropriate panels to provide airflow for cooling and ripening purposes in desired locations of the assembled box. The sleeve can also include two handholds at each end. The purpose of having two handholds is that the box is packed with the bananas crown up and stacked at the plantation with the bananas oriented in this position, meaning that they are shipped in this position. When the bananas leave the ripening rooms, many times the cases are inverted either individually or entire pallets at a time so the bananas are orientated crown down for consumer display; this prevents the need for supermarket personnel to invert each bunch of bananas. Having a mirror image handhold allows the box of bananas to be conveniently carried at both the plantation and at the store level.

The radius on the cut out portion of the handhold can be included, as it helps reduce tearing associated with having a cut end on a vertical flute line. Relief may be cut into the length panel that marries to the glue flap so the sleeve can be put over the corner posts on the tray. The size of the sleeve and trays can be easily modified to accommodate different case counts, products and other desirable variables.

With reference to FIG. 4, the box assembly or container 10 is made up of two of trays 12, and one sleeve 80. In one arrangement, the trays 12 are injection molded from a plastic material having the requisite strength and weight, but could be made of other materials such as metal. As shown in FIG. 1, tray 12 defines sides 38-41. Projecting corner posts 14 are located slightly inside of each corner on the top side 50, at a distance from the edges that is approximately equal to the thickness of sleeve 80. As further shown in FIGS. 1 and 5, each post 14 defines integral sections 16 and 18, one located parallel to each of the edges, and having a length that is approximately related to the length of the side on which it resides; thus section 16 is longer than section 18. Both of sections 16 and 18 have an upper tapered wall portion 20 and a lower vertical wall portion 22. Openings 70 are located just inside of posts 14 and define an open area that is about the size of the area circumscribed by a post, so that the trays can be nested for storage and shipment, as shown in FIG. 7. Trays 12 further comprise four projecting walls or barrier portions 42, one located at about the center of each side of the tray, at the edge.

In one embodiment, tray 12 is about 16 by 20 inches, and posts 14 are about 0.50 inches high. Lower wall portion 22 has a height of about 0.13 inches. Upper wall portion 20 has a height of about 0.37 inches, and is tapered inward at a shallow angle. Barrier portions 42 are about 0.38 inches high and about 4 inches long. Central opening 62 is about 4 by 6 inches. The outer rim of the trays has a thickness of about 0.31 inches, and feet 64 and 65 project below the rim by about 0.19 inches. These dimensions are not critical but are illustrative of a tray that can be used as part of a box for shipping and displaying bananas, as further explained herein.

In one arrangement, the sleeve 80 is die cut from 5 mm thick corrugated polypropylene material, and defines handle cutouts 92 and openings 94, both located on the short sides of the assembled sleeve and shown in FIG. 2; more or fewer openings and/or openings on other of the sleeve sidewalls can be used as desired. In one arrangement, there are two sets of handle cutouts 92 at each short side of the assembled sleeve. These mirror-image handle cutouts allow the assembled box to be easily handled regardless of the orientation of the box. When used for bananas, for example, the mirror-image handle cutouts allow the box to be easily handled whether the product is in the “crown up” or “crown down” positions. Assembly is accomplished by gluing the end flaps together to create a joint area. As shown in FIG. 6, the assembled sleeve can be folded flat along score lines 96-99, as desired. When expanded, sleeve 80 defines open ends 82 and 83 that are sized and shaped to fit a tray 12. When box 10 is assembled, trays 12 comprise the bottom and top, and sleeve 80 defines the box sidewalls 84, 85, 86, 87. One or more strong removable straps of a type known in the art (not shown in the drawings) are used to keep box 10 fully assembled, once the product to be shipped and displayed has been placed into the box.

Box 10 is used as follows. As shown in FIG. 1, a tray 10 is placed on a surface with top 50 facing up. As shown in FIGS. 2 and 3, sleeve 80 is placed edge down on tray 12 such that the sleeve corners are located just outside of posts 14, and the sleeve sidewalls are located just inside of barriers 42. Upper tapered post portions 20 help to guide sleeve 80 into place as it is slipped over the posts, while lower vertical portions 22 help to hold sleeve 80 squared tightly in place. Barriers 42 help to prevent the sleeve sidewalls from bowing outward appreciably when product is placed into the open-top box.

When sleeve 80 is properly located on tray 12, bananas or other product being shipped are placed into the container through open end 82 of sleeve 80, which is the open top of the container. Bananas are placed in the normal shipping position—crown up. When the container is sufficiently filled (typically with about 40 pounds of bananas), a second tray 12 is placed upside down on the open top, with its bottom side 60 facing out, as shown in FIG. 4. One or more straps or other releasable devices that hold the assembly together are then placed, and box 10 is ready to be shipped. Openings 62 and 94 allow for flow of cooling and ripening gases.

For retail display, box 10 is flipped over and placed on a display shelf. The straps are removed. Upper tray 12 and sleeve 80 are removed. This leaves lower tray 12 with product (e.g., bananas) sitting thereon. Store personnel do not need to lift the bananas from the box or turn them upward (crown down) for display. In fact, personnel do not need to handle the bananas in any way.

Once all of the bananas are sold, the empty trays can be stacked and placed on pallets for shipment back to the packing location. Likewise, the sleeves can be folded flat, palletized, and returned for re-use.

As indicated above, the sleeve 80 can be manufactured from a corrugated material, such as a corrugated plastic material. In one arrangement, as indicated in FIG. 2, the sidewalls 84-87 are configured with corrugations 91 that extend from a first end 81 to a second end 83 of the sleeve 80. In such an arrangement, the ends 81, 83 of the sleeve 80 are open to the environment to allow air and fluid to pass there through. In another arrangement, as illustrated in FIG. 8, the walls 84-87 at the first end 81 and the second end 83 of a sleeve 180 are sealed together, to define a set of sealed flutes 126 within the sleeve 80. Each of the sealed flutes 126 includes a longitudinal axis extending between the first end 81 of the sleeve 180 and the second end 83 of the sleeve 80.

For example with reference to FIG. 9, a wall 84 of the sleeve 180 includes a first linerboard 120 and a second linerboard 122 spaced apart from the first linerboard 120. The wall 84 further includes a corrugated sheet 124 disposed between the first and second linerboards 120, 122. During a manufacturing process, a manufacturer compresses the linerboards 120, 122 together at both ends 81, 83 of the sleeve 180 and secures the linerboards 120, 122 to each other at these ends 81, 83. For example, in the case where the linerboards 120, 122 and corrugated sheet 124 are formed from a plastic material, the manufacturer can pinch the linerboards 120, 122 together at respective ends 81, 81 and secure the linerboards 120, 122 together using a mechanical coupling, an adhesive, heat, or an ultrasonic welding process. As indicated in FIG. 10, the manufacturing process creates a set of sealed flutes 126 within the wall 84 where each sealed flute 126 contains a volume of air.

With such a configuration, because the sealed flutes 126 trap air within the wall 84, the sleeve 180 can be manufactured using less material (e.g., plastic) and can be manufactured with a greater stacking strength than conventional sleeves. Additionally, the seal at either end 81, 83 minimizes the introduction of vermin (e.g., insects) and dirt between the linerboards 120, 122

While various embodiments of the innovation have been particularly shown and described, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the innovation as defined by the appended claims. 

What is claimed is:
 1. A box assembly, comprising: (i) at least one tray, comprising: (a) a generally planar portion having four sides that define corresponding edges of the planar portion, each of the four sides defining a corresponding center; (b) a set of projecting walls extending from the surface of the generally planar portion, each projecting wall of the set of projecting walls disposed at a corresponding edge of each corresponding side of the four sides of the planar portion; (d) a corner post disposed at a corresponding corner of a set of four corners of the tray, each corner post spaced inwardly from a first edge and a second edge that define the corresponding corner of the tray; and (ii) a generally rectangular sleeve having a set of four walls that define four corners, a first opening at a first end of the sleeve and a second, opposed opening at a second end of the sleeve, the set of four walls of the first end of the sleeve configured to engage the at least one tray to close the first opening of the sleeve and form a shipping container, the first end of the sleeve configured to be disposed on the at least one tray, the set of four walls of the first end of the sleeve configured to be disposed between the set of projecting walls and the set of corner posts such that an outer surface of each wall is configured to be disposed against each corresponding projecting wall and an inner surface of each corner of the sleeve is configured to be disposed against a corner post of the at least one tray to secure the first end of the sleeve to the at least one tray.
 2. The box assembly of claim 1, wherein each wall of the set of four walls of the sleeve is captured between one projecting wall of the set of projecting walls and two opposing corner posts of the set of corner posts.
 3. The box assembly of claim 1, wherein the sleeve comprises a corrugated material.
 4. The box assembly of claim 3, wherein the corrugated material comprises: a first linerboard and a second linerboard spaced apart from the first linerboard; and a corrugated sheet disposed between the first linerboard and the second linerboard, the corrugated sheet defining a set of sealed flutes having a longitudinal axis extending between the first end of the sleeve and the second end of the sleeve, each sealed flute of the set of sealed flutes configured to contain a volume of air.
 5. The box assembly of claim 4, wherein the corrugated material comprises a corrugated plastic material.
 6. The box assembly of claim 3, wherein the sleeve is configured to be folded into a flat form.
 7. The box assembly of claim 1, wherein at least a portion of each corner post of the set of corner posts are tapered from top to bottom.
 8. The box assembly of claim 7, wherein each post comprises two substantially vertical portions that meet at right angles, each vertical portion defining a taper toward a top end of the corresponding vertical portion, the top end opposing the surface, the taper of each vertical portion defined by an outer surface that is angled inwardly from the vertical reference such that the top end of each vertical portion is more narrow than a base of each vertical portion.
 9. The box assembly of claim 1, wherein each post defines an opening configured to accept an identical post of another tray to allow nesting of the trays.
 10. The box assembly of claim 9, wherein the sleeve defines a plurality of holes in a first wall of the sleeve and in a second wall of the sleeve, the first wall opposing the second wall.
 11. The box assembly of claim 10, wherein the sleeve defines a first handle cutout in the first wall of the sleeve and a second handle cutout in the second wall of the sleeve, the first handle cutout and the second handle cutout being spaced and vertically-aligned.
 12. The reusable combined multi-part product shipping box and display tray of claim 11, wherein each tray has an opening in about a center of, and through, the generally planar portion.
 13. The reusable combined multi-part product shipping box and display tray of claim 1, wherein each wall of the set of four walls of the sleeve is captured between one projecting wall of the set of projecting walls and two opposing corner posts of the set of corner posts. 